Energy storage device with enhanced energy density

Abstract

An energy storage device having improved energy density performance may include an electrolyte having a salt concentration of about 0.6 moles/L (M) to about 0.95M. A final energy storage device product having a total mass of electrolyte that is at least 100% of a saturation quantity of electrolyte sufficient to fully saturate one or more electrode(s) and separator(s) of the device, and below a threshold quantity above the saturation quantity.

What is claimed is: 
     
       1. A final energy storage device product, comprising:
 a container; 
 a first electrode; 
 a second electrode; 
 a separator between the first electrode and the second electrode, wherein the first electrode, second electrode and separator are within the container; and 
 an electrolyte within the container, the electrolyte having a total mass between a saturation quantity and 104% of a saturation quantity of electrolyte; 
 wherein the saturation quantity of electrolyte is the minimum amount of electrolyte in the container that is required to saturate the accessible spaces of the separator, the first electrode and the second electrode. 
 
     
     
       2. The device product of  claim 1 , wherein the mass of the electrolyte is less than or equal to 102% of the saturation quantity of electrolyte. 
     
     
       3. The device product of  claim 2 , wherein the mass of the electrolyte is less than or equal to 101% of the saturation quantity of electrolyte. 
     
     
       4. The device product of  claim 1 , wherein the energy storage device is sealed. 
     
     
       5. The device product of  claim 1 , wherein the energy storage device is configured to operate at an operating voltage of 3 Volts (V). 
     
     
       6. The device product of  claim 1 , wherein the energy storage device comprises a jelly-roll configuration. 
     
     
       7. The device product of  claim 1 , wherein the electrolyte comprises a salt concentration of 0.75 moles/L (M) to 0.95 M. 
     
     
       8. The device product of  claim 1 , wherein at least one of the first electrode and the second electrode comprises a plurality of perforations. 
     
     
       9. The device product of  claim 1 , wherein the electrolyte further comprises:
 a salt concentration selected to reduce precipitation of electrolyte salts within the container, wherein the salt concentration is 0.6 moles/L (M) to 0.95M and acetonitrile. 
 
     
     
       10. The device product of  claim 9 , wherein the electrolyte comprises a salt concentration of 0.8M. 
     
     
       11. The device product of  claim 1 , wherein the electrolyte comprises a quaternary ammonium salt. 
     
     
       12. The device product of  claim 11 , wherein the quaternary ammonium salt comprises a cation selected from the group consisting of spiro-(1,1′)-bipyrrolidinium, triethylmethyl ammonium and tetraethyl ammonium. 
     
     
       13. The device product of  claim 11 , wherein the quaternary ammonium salt comprises tetrafluoroborate. 
     
     
       14. A method of fabricating an energy storage device, comprising:
 providing a container; 
 inserting a first electrode and a second electrode into the container, wherein a separator is positioned between the first electrode and the second electrode; and 
 adding a final, total mass of electrolyte to the container, wherein the total mass is between a saturation quantity and 104% of a saturation quantity of electrolyte; 
 wherein the saturation quantity of electrolyte is the minimum amount of electrolyte in the container that is required to saturate the accessible spaces of the separator, the first electrode and the second electrode. 
 
     
     
       15. The method of  claim 14 , wherein adding the total mass of the electrolyte comprises adding a mass of electrolyte less than or equal to 102% of the saturation quantity of electrolyte. 
     
     
       16. The method of  claim 14 , further comprising sealing the energy storage device. 
     
     
       17. The method of  claim 14 , wherein the energy storage device comprises an ultracapacitor. 
     
     
       18. The method of  claim 14 , wherein adding the mass of the electrolyte comprises adding an electrolyte having a salt concentration of 0.7 M to 0.95 M, and wherein the salt comprises at least one of tetraethyl ammonium tetrafluoroborate and spiro-(1,1′)-bipyrrolidinium tetrafluoroborate. 
     
     
       19. The method of  claim 14 , wherein adding the total mass of electrolyte comprises adding an additional 3 grams (g) or less of electrolyte in addition to the saturation quantity of electrolyte. 
     
     
       20. The method of  claim 14 , wherein adding the electrolyte comprises adding an electrolyte having a salt concentration of 0.6M to 0.95M and acetonitrile. 
     
     
       21. The method of  claim 20 , wherein adding the electrolyte comprises adding an electrolyte having salt concentration of 0.8M. 
     
     
       22. The method of  claim 14 , wherein adding the electrolyte comprises adding at least one of a spiro-(1,1′)-bipyrrolidinium tetrafluoroborate, triethylmethyl ammonium tetrafluoroborate and tetraethyl ammonium tetrafluoroborate. 
     
     
       23. A method of fabricating an energy storage device, comprising:
 providing a container; 
 inserting a first electrode and a second electrode into the container, wherein a separator is positioned between the first electrode and the second electrode; and 
 adding a final, total mass of electrolyte to the container with an electrolyte injection tool, wherein the total mass corresponds to the saturation quantity of electrolyte combined with an additional mass of electrolyte corresponding to the manufacturing tolerance of the electrolyte injection tool, wherein the saturation quantity of electrolyte is the minimum amount of electrolyte in the container that is required to saturate the accessible spaces of the separator, the first electrode and the second electrode.